Information injection-pump assembly
ZEXEL
101402-3750
1014023750
KOMATSU
6135721411
6135721411
Rating:
Service parts 101402-3750 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6-13612-310-0
12.
Open Pre:MPa(Kqf/cm2)
22.1(225)
15.
NOZZLE SET
Cross reference number
ZEXEL
101402-3750
1014023750
KOMATSU
6135721411
6135721411
Zexel num
Bosch num
Firm num
Name
101402-3750
6135721411 KOMATSU
INJECTION-PUMP ASSEMBLY
SA4D105 * K
SA4D105 * K
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-2-4-3
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5
Cyl.1-2 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5
Cal 1-3 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.4
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
125.3
124.3
126.3
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
4.7+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
10.5
9
12
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
----------
K=7
----------
----------
K=7
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=31deg+-5deg b=37deg+-5deg
----------
----------
a=31deg+-5deg b=37deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=27deg+-5deg b=53deg+-5deg
----------
----------
a=27deg+-5deg b=53deg+-5deg
0000001501 Q ADJUSTMENT PIPING
Fuel hose piping outline
Tester fuel pipe A
(B) branch piping
Fuel hose C
(D) Fuel inlet
1. Because the pump gallery is divided into two, be careful of the fuel piping at adjustment.
(1)Connect the fuel inlet hose (C) to the port and connect the branch pipe.
(2)Connect the tester fuel piping to the branch pipe.
----------
----------
----------
----------
Timing setting
(1)Pump vertical direction
(2)Position of camshaft's key groove at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
Problem
Under certain operating conditions, customers may complain of slow response and black smoke on certain 435 HP 3208 TA Marine Engines.
Affected Product
Model & Identification Number
Group 1
3208 (01Z25415-25417, 01Z25462, 01Z25463, 01Z25468-25470, 01Z25472, 01Z25475, 01Z25477, 01Z25481, 01Z25486, 01Z25491-25494, 01Z25499, 01Z25500, 01Z25541-25544, 01Z25554, 01Z25555, 01Z25574, 01Z25578, 01Z25579, 01Z25582, 01Z25584-25591, 01Z25596, 01Z25599-25602, 01Z25604, 01Z25605, 01Z25607-25617, 01Z25619, 01Z25620, 01Z25622-25625, 01Z25627, 01Z25629-25635, 01Z25639, 01Z25641-25643, 01Z25650-25652, 01Z25654, 01Z25655, 01Z25661, 01Z25664-25666, 01Z25668, 01Z25671, 01Z25673, 01Z25674, 01Z25678, 01Z25682, 01Z25683, 01Z25686-25688, 01Z25692, 01Z25693, 01Z25696-25698, 01Z25700-25702, 01Z25705-25707, 01Z25711-25717, 01Z25719, 01Z25720, 01Z25722, 01Z25724, 01Z25726, 01Z25728, 01Z25729, 01Z25736, 01Z25738, 01Z25742, 01Z25748, 01Z25750, 01Z25751, 01Z25753, 01Z25755, 01Z25760, 01Z25762, 01Z25764, 01Z25766, 01Z25771, 01Z25773, 01Z25775, 01Z25805-25807, 01Z25815-25817, 01Z25822, 01Z25823, 01Z25829-25833, 01Z25839-25841, 01Z25851-25853, 01Z25857-25860, 01Z25866-25872, 01Z25874, 01Z25876-25878, 01Z25880, 01Z25884-25890, 01Z25892, 01Z25894-25899, 01Z25901-25906, 01Z25909-25914, 01Z25916, 01Z25919-25923, 01Z25925, 01Z25927-25934, 01Z25938-25941, 01Z25944, 01Z25946, 01Z25948, 01Z25951-25953, 01Z25961, 01Z25962, 01Z25964, 01Z25966, 01Z25970-25973, 01Z25977, 01Z25978, 01Z25983, 01Z25984, 01Z25986-25988, 01Z25991-25995, 01Z25997, 01Z25999-26002, 01Z26004, 01Z26006-26014, 01Z26016-26018, 01Z26022, 01Z26023, 01Z26025-26027, 01Z26029-26032, 01Z26034-26051, 01Z26053-26062, 01Z26065, 01Z26066, 01Z26068, 01Z26070, 01Z26071, 01Z26073, 01Z26075-26088, 01Z26090-26107, 01Z26110-26113, 01Z26118-26121, 01Z26123, 01Z26124, 01Z26126-26128, 01Z26130-26133, 01Z26135-26140, 01Z26145-26149, 01Z26153-26155, 01Z26160-26162, 01Z26166, 01Z26169, 01Z26174, 01Z26175, 01Z26180, 01Z26181, 01Z26183-26187, 01Z26189, 01Z26193-26196, 01Z26200, 01Z26202, 01Z26205, 01Z26207, 01Z26218, 01Z26220, 01Z26226, 01Z26233-26235, 01Z26238, 01Z26245, 01Z26253, 01Z26254, 01Z26262, 01Z26264, 01Z26266, 01Z26270-26272, 01Z26274, 01Z26276, 01Z26282-26284, 01Z26289-26291, 01Z26296, 01Z26302-26305, 01Z26307, 01Z26308, 01Z26310, 01Z26311, 01Z26313, 01Z26315-26329, 01Z26331-26341, 01Z26343, 01Z26347-26349, 01Z26352-26356, 01Z26358, 01Z26359, 01Z26363-26367, 01Z26371, 01Z26372, 01Z26375, 01Z26377, 01Z26378, 01Z26381-26383, 01Z26385-26393, 01Z26395-26399, 01Z26401, 01Z26402, 01Z26406, 01Z26407, 01Z26409, 01Z26410, 01Z26415, 01Z26416, 01Z26420-26423, 01Z26425, 01Z26427-26431, 01Z26433, 01Z26435, 01Z26444-26448, 01Z26458-26462, 01Z26465-26475, 01Z26483, 01Z26484, 01Z26488-26507, 01Z26510-26513, 01Z26519, 01Z26521, 01Z26522, 01Z26525, 01Z26537-26540, 01Z26546-26549, 01Z26551-26555, 01Z26563, 01Z26568, 01Z26569, 01Z26571, 01Z26572, 01Z26587, 01Z26589, 01Z26593, 01Z26594, 01Z26599-26601, 01Z26606, 01Z26607, 01Z26611, 01Z26618, 01Z26622-26626, 01Z26628-26644, 01Z26646-26648, 01Z26651-26656, 01Z26658, 01Z26660, 01Z26662, 01Z26664, 01Z26666, 01Z26668, 01Z26670, 01Z26672-26674, 01Z26677-26682, 01Z26684-26686, 01Z26691, 01Z26692, 01Z26709-26712, 01Z26716-26722, 01Z26726, 01Z26727, 01Z26732-26736, 01Z26738, 01Z26745-26748, 01Z26750-26757, 01Z26760-26769, 01Z26771-26779, 01Z26785-26787, 01Z26792-26803, 01Z26810-26814, 01Z26818-26820, 01Z26823-26825, 01Z26828-26833, 01Z26836-26848, 01Z26850-26852, 01Z26854, 01Z26857, 01Z26862, 01Z26867, 01Z26868, 01Z26872, 01Z26873, 01Z26875, 01Z26876, 01Z26880, 01Z26886, 01Z26887, 01Z26889-26891, 01Z26897, 01Z26899-26901, 01Z26907, 01Z26909, 01Z26910, 01Z26912, 01Z26915-26920, 01Z26922, 01Z26925-26931, 01Z26933, 01Z26936-26941, 01Z26947-26949, 01Z26951-26956, 01Z26960-26962, 01Z26968, 01Z26974-26977, 01Z26983, 01Z26988, 01Z26990, 01Z26991, 01Z26994, 01Z26995, 01Z26997, 01Z27001-27005, 01Z27007-27009, 01Z27012, 01Z27013, 01Z27016, 01Z27017, 01Z27023-27027, 01Z27029, 01Z27031, 01Z27033, 01Z27035-27042, 01Z27044, 01Z27049, 01Z27050, 01Z27058, 01Z27060, 01Z27063-27066, 01Z27069-27081)
Group 2
3208 (01Z27085-27089, 01Z27092-27096, 01Z27098, 01Z27099, 01Z27103-27105, 01Z27112, 01Z27114-27117, 01Z27236, 01Z27238, 01Z27243, 01Z27249-27253, 01Z27260, 01Z27261, 01Z27269, 01Z27270, 01Z27275, 01Z27277, 01Z27279, 01Z27281, 01Z27295, 01Z27297-27300, 01Z27302, 01Z27304-27306, 01Z27308, 01Z27310-Up01Z27315, 01Z27317, 01Z27320-27327, 01Z27329-27331, 01Z27334, 01Z27335)
Parts Needed
Group 1
1 - 7M7273 Gasket-Turbo4 - 2N2766 Locknut1 - 1S4810 Gasket1 - 1S6595 Gasket1 - 1055060 Turbo Group-Basic8 - 1153354 Nozzle Assembly-Fuel InjectorGroup 2
8 - 1153354 Nozzle Assembly-Fuel InjectorAction Required
Parts Stock
Remove all 1005866 Turbocharger Groups and 1010060 Fuel Injection Nozzle Assemblies from Parts Stock.
Group 1
Replace the existing turbocharger and fuel injection nozzles with a new 1055060 Basic Turbocharger Group and eight new 1153354 Fuel Injection Nozzle Assemblies.
Group 2
Replace the existing fuel injection nozzles with eight new 1153354 Fuel Injection Nozzle Assemblies.
If "GD" is stamped on the front cover, the rework has already been performed. Do not perform the rework again.
Service Claim Allowances
Parts Stock
Submit one claim for all 1005866 Turbocharger Groups and 1010060 Fuel Injection Nozzle Assemblies removed from Parts Stock.
US and
Under certain operating conditions, customers may complain of slow response and black smoke on certain 435 HP 3208 TA Marine Engines.
Affected Product
Model & Identification Number
Group 1
3208 (01Z25415-25417, 01Z25462, 01Z25463, 01Z25468-25470, 01Z25472, 01Z25475, 01Z25477, 01Z25481, 01Z25486, 01Z25491-25494, 01Z25499, 01Z25500, 01Z25541-25544, 01Z25554, 01Z25555, 01Z25574, 01Z25578, 01Z25579, 01Z25582, 01Z25584-25591, 01Z25596, 01Z25599-25602, 01Z25604, 01Z25605, 01Z25607-25617, 01Z25619, 01Z25620, 01Z25622-25625, 01Z25627, 01Z25629-25635, 01Z25639, 01Z25641-25643, 01Z25650-25652, 01Z25654, 01Z25655, 01Z25661, 01Z25664-25666, 01Z25668, 01Z25671, 01Z25673, 01Z25674, 01Z25678, 01Z25682, 01Z25683, 01Z25686-25688, 01Z25692, 01Z25693, 01Z25696-25698, 01Z25700-25702, 01Z25705-25707, 01Z25711-25717, 01Z25719, 01Z25720, 01Z25722, 01Z25724, 01Z25726, 01Z25728, 01Z25729, 01Z25736, 01Z25738, 01Z25742, 01Z25748, 01Z25750, 01Z25751, 01Z25753, 01Z25755, 01Z25760, 01Z25762, 01Z25764, 01Z25766, 01Z25771, 01Z25773, 01Z25775, 01Z25805-25807, 01Z25815-25817, 01Z25822, 01Z25823, 01Z25829-25833, 01Z25839-25841, 01Z25851-25853, 01Z25857-25860, 01Z25866-25872, 01Z25874, 01Z25876-25878, 01Z25880, 01Z25884-25890, 01Z25892, 01Z25894-25899, 01Z25901-25906, 01Z25909-25914, 01Z25916, 01Z25919-25923, 01Z25925, 01Z25927-25934, 01Z25938-25941, 01Z25944, 01Z25946, 01Z25948, 01Z25951-25953, 01Z25961, 01Z25962, 01Z25964, 01Z25966, 01Z25970-25973, 01Z25977, 01Z25978, 01Z25983, 01Z25984, 01Z25986-25988, 01Z25991-25995, 01Z25997, 01Z25999-26002, 01Z26004, 01Z26006-26014, 01Z26016-26018, 01Z26022, 01Z26023, 01Z26025-26027, 01Z26029-26032, 01Z26034-26051, 01Z26053-26062, 01Z26065, 01Z26066, 01Z26068, 01Z26070, 01Z26071, 01Z26073, 01Z26075-26088, 01Z26090-26107, 01Z26110-26113, 01Z26118-26121, 01Z26123, 01Z26124, 01Z26126-26128, 01Z26130-26133, 01Z26135-26140, 01Z26145-26149, 01Z26153-26155, 01Z26160-26162, 01Z26166, 01Z26169, 01Z26174, 01Z26175, 01Z26180, 01Z26181, 01Z26183-26187, 01Z26189, 01Z26193-26196, 01Z26200, 01Z26202, 01Z26205, 01Z26207, 01Z26218, 01Z26220, 01Z26226, 01Z26233-26235, 01Z26238, 01Z26245, 01Z26253, 01Z26254, 01Z26262, 01Z26264, 01Z26266, 01Z26270-26272, 01Z26274, 01Z26276, 01Z26282-26284, 01Z26289-26291, 01Z26296, 01Z26302-26305, 01Z26307, 01Z26308, 01Z26310, 01Z26311, 01Z26313, 01Z26315-26329, 01Z26331-26341, 01Z26343, 01Z26347-26349, 01Z26352-26356, 01Z26358, 01Z26359, 01Z26363-26367, 01Z26371, 01Z26372, 01Z26375, 01Z26377, 01Z26378, 01Z26381-26383, 01Z26385-26393, 01Z26395-26399, 01Z26401, 01Z26402, 01Z26406, 01Z26407, 01Z26409, 01Z26410, 01Z26415, 01Z26416, 01Z26420-26423, 01Z26425, 01Z26427-26431, 01Z26433, 01Z26435, 01Z26444-26448, 01Z26458-26462, 01Z26465-26475, 01Z26483, 01Z26484, 01Z26488-26507, 01Z26510-26513, 01Z26519, 01Z26521, 01Z26522, 01Z26525, 01Z26537-26540, 01Z26546-26549, 01Z26551-26555, 01Z26563, 01Z26568, 01Z26569, 01Z26571, 01Z26572, 01Z26587, 01Z26589, 01Z26593, 01Z26594, 01Z26599-26601, 01Z26606, 01Z26607, 01Z26611, 01Z26618, 01Z26622-26626, 01Z26628-26644, 01Z26646-26648, 01Z26651-26656, 01Z26658, 01Z26660, 01Z26662, 01Z26664, 01Z26666, 01Z26668, 01Z26670, 01Z26672-26674, 01Z26677-26682, 01Z26684-26686, 01Z26691, 01Z26692, 01Z26709-26712, 01Z26716-26722, 01Z26726, 01Z26727, 01Z26732-26736, 01Z26738, 01Z26745-26748, 01Z26750-26757, 01Z26760-26769, 01Z26771-26779, 01Z26785-26787, 01Z26792-26803, 01Z26810-26814, 01Z26818-26820, 01Z26823-26825, 01Z26828-26833, 01Z26836-26848, 01Z26850-26852, 01Z26854, 01Z26857, 01Z26862, 01Z26867, 01Z26868, 01Z26872, 01Z26873, 01Z26875, 01Z26876, 01Z26880, 01Z26886, 01Z26887, 01Z26889-26891, 01Z26897, 01Z26899-26901, 01Z26907, 01Z26909, 01Z26910, 01Z26912, 01Z26915-26920, 01Z26922, 01Z26925-26931, 01Z26933, 01Z26936-26941, 01Z26947-26949, 01Z26951-26956, 01Z26960-26962, 01Z26968, 01Z26974-26977, 01Z26983, 01Z26988, 01Z26990, 01Z26991, 01Z26994, 01Z26995, 01Z26997, 01Z27001-27005, 01Z27007-27009, 01Z27012, 01Z27013, 01Z27016, 01Z27017, 01Z27023-27027, 01Z27029, 01Z27031, 01Z27033, 01Z27035-27042, 01Z27044, 01Z27049, 01Z27050, 01Z27058, 01Z27060, 01Z27063-27066, 01Z27069-27081)
Group 2
3208 (01Z27085-27089, 01Z27092-27096, 01Z27098, 01Z27099, 01Z27103-27105, 01Z27112, 01Z27114-27117, 01Z27236, 01Z27238, 01Z27243, 01Z27249-27253, 01Z27260, 01Z27261, 01Z27269, 01Z27270, 01Z27275, 01Z27277, 01Z27279, 01Z27281, 01Z27295, 01Z27297-27300, 01Z27302, 01Z27304-27306, 01Z27308, 01Z27310-Up01Z27315, 01Z27317, 01Z27320-27327, 01Z27329-27331, 01Z27334, 01Z27335)
Parts Needed
Group 1
1 - 7M7273 Gasket-Turbo4 - 2N2766 Locknut1 - 1S4810 Gasket1 - 1S6595 Gasket1 - 1055060 Turbo Group-Basic8 - 1153354 Nozzle Assembly-Fuel InjectorGroup 2
8 - 1153354 Nozzle Assembly-Fuel InjectorAction Required
Parts Stock
Remove all 1005866 Turbocharger Groups and 1010060 Fuel Injection Nozzle Assemblies from Parts Stock.
Group 1
Replace the existing turbocharger and fuel injection nozzles with a new 1055060 Basic Turbocharger Group and eight new 1153354 Fuel Injection Nozzle Assemblies.
Group 2
Replace the existing fuel injection nozzles with eight new 1153354 Fuel Injection Nozzle Assemblies.
If "GD" is stamped on the front cover, the rework has already been performed. Do not perform the rework again.
Service Claim Allowances
Parts Stock
Submit one claim for all 1005866 Turbocharger Groups and 1010060 Fuel Injection Nozzle Assemblies removed from Parts Stock.
US and
Have questions with 101402-3750?
Group cross 101402-3750 ZEXEL
Komatsu
101402-3750
6135721411
INJECTION-PUMP ASSEMBLY
SA4D105
SA4D105